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Disassembly and Assembly: 2506-15 Industrial Engine
Disassembly and Assembly: 2506-15 Industrial Engine
Disassembly and Assembly: 2506-15 Industrial Engine
August 2006
Disassembly and
Assembly
2506-15 Industrial Engine
MGA (Engine)
MGB (Engine)
MGD (Engine)
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Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
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KENR6232 3
Table of Contents
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4 KENR6232
Disassembly and Assembly Section
Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01279497
Dispose of all fluids according to local regulations and Illustration 2
mandates.
1. Position a new joint (3) on fuel filter base (4).
NOTICE Note: Ensure correct orientation of the joint.
Keep all parts clean from contaminants.
2. Position the fuel priming pump assembly (1) on
Contaminants may cause rapid wear and shortened the fuel filter base and install bolts (2). Tighten the
component life. 1/4" bolt to a torque of 12 N·m (105 lb in). Tighten
the 5/16" bolt to a torque of 25 N·m (221 lb in).
1. Turn the fuel supply to the “OFF” position.
3. Turn the fuel supply to the “ON” position.
i02554755
Removal Procedure
Illustration 1
g01279497 NOTICE
Care must be taken to ensure that fluids are contained
2. Remove bolts (2). Remove fuel priming pump during performance of inspection, maintenance, test-
assembly (1) from fuel filter base (4). ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
3. Remove joint (3) from the fuel priming pump ing any compartment or disassembling any compo-
assembly and the fuel filter base. nent containing fluids.
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KENR6232 5
Disassembly and Assembly Section
i02554753
NOTICE
Keep all parts clean from contaminants.
Fuel Filter Base - Disassemble
Contaminants may cause rapid wear and shortened
component life.
Disassembly Procedure
1. Turn the fuel supply to the “OFF” position. Start By:
NOTICE
Keep all parts clean from contaminants.
g01279811
Illustration 3
3. Remove plugs (9) and (11). Allow the fuel to drain. 1. Remove fuel priming pump (4) from fuel filter
base assembly (1). Refer to Disassembly and
4. Disconnect harness assembly (1) from fuel Assembly, “Fuel Priming Pump - Remove and
temperature sensor (2). Install”.
Note: In order to disconnect the harness assembly, 2. Remove fuel temperature sensor (2) from fuel
slide the locking tab into the unlocked position. filter base assembly (1). Refer to Disassembly and
Assembly, “Fuel Temperature Sensor - Remove
5. Disconnect hose assembly (3). Disconnect hose and Install”.
assembly (5). Disconnect hose assemblies (7)
and (8). Plug the open hose assemblies. 3. Remove fuel bypass valve (6) from fuel filter base
assembly (1). Remove the O-ring seals from the
6. Use a suitable tool with a 1/2" square drive fuel bypass valve.
in order to remove fuel filter assemblies (10)
and (12). Remove the O-ring seals. Remove 4. Remove fuel check valve (10) from fuel filter base
the fuel filter elements. Refer to Operation and assembly (1). Remove the O-ring seals from the
Maintenance Manual, “Fuel Filter - Replace” for fuel check valve.
more information.
5. Remove connections (3), (5), (7) and (8) from fuel
7. Remove bolts (4). Remove fuel filter base (6). filter base assembly (1). Remove the O-ring seals
from the connections.
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6 KENR6232
Disassembly and Assembly Section
1. Ensure that the filter base is clean and free from i02554754
damage. If necessary, replace the filter base.
Fuel Filter Base - Install
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
g01279898
Illustration 5
5. Install new O-ring seals to fuel check valve (10). 1. Position fuel filter base (6) and install bolts (4).
Install the fuel check valve in fuel filter base Tighten the bolts to a torque of 47 N·m (35 lb ft).
assembly (1). Tighten the fuel check valve to a
torque of 35 N·m (26 lb ft). 2. Install new O-ring seals and new fuel filter
elements to fuel filter assemblies (10) and (12).
Use a suitable tool with a 1/2" square drive in
order to install the fuel filter assemblies.
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KENR6232 7
Disassembly and Assembly Section
g01280943
Illustration 8
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8 KENR6232
Disassembly and Assembly Section
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 27610288 Pry Bar 1
Start By:
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KENR6232 9
Disassembly and Assembly Section
i02554719
Installation Procedure
Table 2
Required Tools
Tool Part Part Description Qty
Number
GE50028 Vacuum Pump 1
g01073439
Illustration 11 GE50046 Fluid Sampling Bottle 1
B
7. Use Tooling (A) to pry beneath the base and free Tube
GE50030 1
7.9 mm (0.31 inch) OD
electronic unit injector (2).
C - Large Bore Brush 1
8. Remove electronic unit injector (2) and clamp (6)
from the cylinder head. Surface Reconditioning
D 27610308 1
Pad
E 27610296 Torque Wrench 1
NOTICE
Keep all parts clean from contaminants.
g01284074
Illustration 13
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10 KENR6232
Disassembly and Assembly Section
5. Install a new O-ring seal (13) on the electronic unit Note: Ensure that used valve bridges are reinstalled
injector. in the original location and the original orientation.
Do not interchange the location or the orientation of
Note: O-ring seal (13) should be installed dry. used valve bridges.
NOTICE 11. Install the rocker arms and the rocker arm shaft.
If a replacement electronic unit injector is installed, the Refer to Disassembly and Assembly, “Rocker Arm
calibration code must be programmed into the elec- and Shaft - Install”.
tronic control module. Refer to Troubleshooting Guide,
“Injector Trim File” for more information. 12. Turn the fuel supply to the “ON” position.
i02554722
Removal Procedure
g01150587 Table 3
Illustration 14
Required Tools
6. Install clamp (6) to electronic unit injector (2). Tool Part Number Part Description Qty
Install electronic unit injector (2) into the original
location in the cylinder head. A GE50021 Injector Sleeve Tool 1
7. Install spacer (5) and bolt (4). Tighten bolt (4) to a Start By:
torque of 55 N·m (41 lb ft).
a. Remove the electronic unit injectors. Refer to
Disassembly and Assembly, “Electronic Unit
Injector - Remove”.
NOTICE
Keep all parts clean from contaminants.
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KENR6232 11
Disassembly and Assembly Section
NOTICE
Ensure that the electronic unit injector sleeve and the
cylinder head bore are completely free of oil, dirt, and
sealant debris.
g01076133
Illustration 16
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12 KENR6232
Disassembly and Assembly Section
i02554785
Turbocharger - Remove
Removal Procedure
Start By:
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
NOTICE
Keep all parts clean from contaminants.
g01283022
Illustration 18
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KENR6232 13
Disassembly and Assembly Section
i02554784
Turbocharger - Install
Installation Procedure
Table 5
Required Tools
Tool Part Part Description Qty
Number
A CV60889 Anti-Seize Compound 1
NOTICE
Keep all parts clean from contaminants.
g01283022
Illustration 19
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14 KENR6232
Disassembly and Assembly Section
6. Install tube clamp (9) to tube assembly (7) to tube 5. If necessary, remove the taperlock studs from the
assembly (8). cylinder head.
Removal Procedure
Start By:
g01283599
Illustration 21
Illustration 20
g01283599 5. Apply Tooling (A) to the threads of the taperlock
studs. Install spacers (1), washers (2) and
1. Remove locknuts (3), washers (2) and spacers (1). locknuts (3).
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KENR6232 15
Disassembly and Assembly Section
i02554738
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
i02554768
Illustration 23
g01296103
Removal Procedure
1. Use an allen wrench in order to loosen clamp (1) Table 7
that secures the exhaust elbow. Required Tools
2. Remove the exhaust elbow and the clamp from Tool Part Number Part Description Qty
the turbocharger. A CH11148 Engine Turning Tool 1
B GE50026 Valve Spring Compressor 1
This document has been printed from SPI². Not for Resale
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